Connector Terminal Step for Resin Sealing Waterproofing
Find Innovative SolutionsGenerate Solutions
Solution Overview
Problem
The existing electric wire connection structure of connector terminals, when sealed with a resin mold, experiences poor adhesion between the terminal and the housing, leading to potential water infiltration due to the thin resin coverage at the sheath crimping section, necessitating additional work on the connector housing to enhance sealing.
Innovation Solution
A step is introduced between the conductor and sheath crimping sections of the connector terminal, allowing for increased resin mold thickness and coverage, ensuring sufficient waterproofing without requiring special modifications to the connector housing, and the method involves forming this step during the crimping process using a pressure molding die with stepped mold faces.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Reliability
If the connector terminal is sealed with a resin mold to provide waterproofing, then corrosion protection is improved, but the adhesion between the terminal and housing deteriorates due to poor contact between the terminal underside and housing inner bottom face
Solution Approach 1:
The invention introduces a stepped configuration that creates a vertical dimension difference between the front and rear portions of the terminal underside. The rear portion is positioned higher than the front portion, forming a step structure that allows the resin to be applied thicker at the rear while maintaining proper adhesion at the front contact area with the housing.
2Reliability
If the resin mold thickness is increased to improve sealing performance, then waterproofing is enhanced, but the connector housing requires additional work or modifications
Solution Approach 1:
The stepped configuration is pre-formed on the terminal itself during the molding process, before the terminal is installed into the housing. This preliminary structuring of the terminal allows the resin to be applied with varied thickness without requiring any subsequent modifications to the housing structure.
3Reliability
If the terminal underside is completely covered with resin to ensure waterproofing, then corrosion protection is improved, but the adhesion to housing deteriorates due to lack of direct contact
Solution Approach 1:
The invention applies different resin thicknesses to different areas of the terminal underside. The front portion maintains thin or no resin coverage to ensure direct contact and adhesion with the housing, while the rear portion receives thicker resin coverage to provide adequate corrosion protection and sealing where the wire connection is located.
Applied Scientific Principles
This section explains which scientific principles are used to turn an abstract innovation direction into a practical engineering solution.
Function Achieved in This Case
This configuration enhances the sealing performance of the resin mold, providing adequate waterproofing and stable accommodation of the connector terminal within the housing without additional work on the housing, effectively preventing water infiltration and ensuring corrosion protection.
Implementation Method 1
an underside of the connector terminal is put on a mold face 1a of a lower mold 1 of a pressure molding die... An upper mold 2 is lowered in this state as indicated by arrow A3, thereby rolling the pair of crimping pieces
Implementation Method 2
the connection between the electric wire W and the connector terminal 10 is molded, if needed, of a resin so as to cover an entire bare portion of the conductor Wa. The wire connection is sealed with a resin mold 20, thereby protecting the conductor Wa against corrosion and rendering the same waterproof
Data Source
AI summary
It is an objective to enhance sealing performance of a resin mold without subjecting a connector housing to special work. In an electric wire connection structure of a connector terminal in which an end of an electric wire (W) is connected to a rear portion of a connector terminal (10) and in which the electric wire connection is sealed of a resin mold (20), a step (d) that makes an underside (13b) of a rearmost end of the connector terminal (10) higher than an underside of an area ahead of the rearmost end is provided between the underside (13b) of the rearmost end and the underside (12b) ahead of the rearmost end, thereby assuring space (22) that enables filling of a resin which makes up a resin mold (20).